Preparation of modified methyl methacrylate compositions



- single halogen atom, at a 150 C. under autogenous pressure.

Patented Oct. 1, 1946 i PATENT OFFICE PREPARATION OF MODIFIED METHYL METHACRYLATE COMPOSITIONS Claymont, Del., assignor to E. I. du Pont de Nemours & Company, Wilmington, DeL, a corporation of Delaware No Drawing. Application January 12, 1943, Serial N0. 472,161

Frederick L. Johnston,

' 2 Claims.

This invention relates to the preparation of" modified methyl methacrylate compositions and, more particularly, to give molded articles characterized by high resistance to distortion by heat.

Heretofore methyl methacrylate monomer has been polymerized to yield thermoplastic molding compositions. When such polymers are prepared by heating methyl methacrylate monomer in the absence of catalysts or in the presence of small concentrations of peroxide-type catalysts, the resulting molding compositions are difficult to fuse into optically homogeneous masses under heat and pressure, and, when hot, are too viscous for satisfactory molding by injection. In the past these objections have been partly overcome by various means but an outstanding difflculty has been to obtain a product which can be molded into, articles that do not tend to distort at undesirably low temperatures; particularly, has this been the case where the articles have been injection molded although it also holds to a considerable extent with respect to compression molded articles. A further difllculty is to obtain a product improved in this characteristic and at the same time characterized by good moldability and yielding molded products having optical homogeneity and being free from discoloration.

An object of the present invention is to provide an improved methyl methacrylate composition characterized by good moldability and adapted to be molded into articles having high resistance to distortion by heat, optical homogeneity, and freedom from discoloration. A further and more particular object is to provide a composition adapted to be injection molded into articles having high resistance to distortion by heat. A still further object is to provide a practical and economical method of preparing such compositions. Other objects will be apparent from the description of the inventiongiven hereinafter.

The above objects are accomplished according to the present invention by polymerizing monomeric methyl methacrylate in the presence of very small amounts, of unsymmetrical alpha-olefinic compounds in which one of the carbon atoms of the double bond carries a single, halogen atom.

More specifically, the polymerized methyl methacrylate composition of the present invention is prepared by polymerizing a dispersion of monomeric methyl methacrylate in a non-solvent liquid such as water in the presence of 0.01% to 3.0%, by weight of the monomer, of an unsymmetrical alpha-olefinic compound in which one of the carbon atoms of the double bond carries a temperature of 100 C.-

to such compositions adapted invention,

In the preferred method of carrying out this small amounts of benzoyl peroxide and the selected halo-olefin are dissolved in methyl methacrylate monomer. This solution is suspended in about twice its volume of water. water contains a small proportion of a mild dispersing agent such as the 65% sodium salt of polymethacrylic acid and is buffered to a pH of about 7.5 by means of a suitable inorganic salt. This mixture is agitated vigorously in a closed reaction vessel capable of withstanding moderate pressures. The polymerization is carried out by heating at a temperature in the neighborhood of 125 C. under a pressure of about 50 lbs/sq. in. for twenty to thirty minutes until the essential completion of polymerization is indicated by a sudden drop in pressure due to the essential disappearance of monomeric methyl methacrylate. It is preferable to prevent the reaction from becoming too violent by suitable cooling of the vessel. The mixture is then cooled and discharged from the reaction vessel. The granular product is separated from the mother liquor, washed, centrifuged, and dried by heating at C to C. in a circulating air oven or under vacuum, and this dried granular polymer is then masticated on hot mixing rolls for ten to fifteen minutes, removed from the rolls, cooled and comminuted to pass a screen. Thev resulting product is suitable for compression or injection molding and shows special advantages when used for the latter purpose.

The following examples illustrate specific embodiments of the composition and the method of preparing same according to the present invention,

Exmu: I

The following solutions are made up of:

Parts Distilled water NazHPO4.12H2O 1% Water solution of polymethacrylic acid (a) are dissolved together lined closed re- The ingredients in and charged into a glass enamel all parts being given by weight unless otherwise specified:

action kettle capable of withstanding pressures up to 300 lbsJsqin. and fitted with a stainless steel anchor shaped stirrer, stainless steel baflles, thermocouple for observing the temperature of the contents, and an outlet through the head to a pressure gauge. The catalyst (c) is freshly dissolved in (b) and the resulting solutionis charged at once into the reaction kettle. The kettle is sealed and th stirrer operated at 575 R. P. M. throughout the run. External heat is applied to bring the kettle contents, to a temperature of 110 C. within fifteen to twenty minutes at which time the pressure gauge shows about 45 lbs./sq.in. pressure. The heat is then shut oil". Within one to two minutes the exothermic polymerization reaction begins and there is a surge of temperature and pressure to 114 C. and 53 lbs./sq.in., respectively, where the bulk of the polymerization takes place. Within about. five minutes there is a rapid decrease in pressure to about lbs./sq.in. and the temperature begins to drop. Stirring is continued until the kettle contents have cooled to 40 C. or. below at which time the pressure gauge shows zero pressure and the kettle is opened. The product, in the form of crystal clear spherical granules up to about /64" diameter, is removed from the mother liquor on filter cloth the washings are clear. This requires a total of about 20,000 parts of wash water. Excesswater is removed by means of a centrifuge and the prodvacuum. a

The fine granular product is converted to molding powder suitable for injection molding by hot pressing into sheets at 160 0., followed by chopping into particles which will pass a screen. This molding compound is then injection molded in an injection molding machine, suitably a l-ounce capacity De Mattia vertical injection molding machine built by the De Mattie. Machine and Tool Company, Clifton, N. J. The machine is supplied with a die capable of molding test specimens whose measurements are 2 /2" x /z" x 0.065". The polymer is injected into the die through agate at the end of the cavity with the die closing and injection taking place during a period of 1.25 seconds. The machine is timed to maintain piston pressure on the molding powder and clamping pressure on the die simultaneously for fifteen seconds to enable the molding to set up in the die. A new injection is made every sixty seconds. The polymer may be molded under several temperature conditions to yield specimens of attractive appearance. When the heating cylinder delivers polymer. at 220 C. into the cold die, satisfactory moldings are produced under 22,700 lbs./sq.in. piston pressure. Moldings of excellent clarity and surface characteristics are obtained which are faithful reproductions of the die cavity. Injection moldedstrips molded as above are found to soften at 86 C. according to the following method.

The strip 2%" x /2''' x 0.065" is mounted horizontally by one end in a clamp, cantilever fashion, the supported end sticking 4" into a vertical slot in the clamp so that the strip is supported 34;" from the end. At a spot A" from the opposite end on the upper edge a weight of 27.5 g. is placed so that it rests entirely on-the test strip and is free to move up or down with the strip. The assembly (excepting the weight) is immersed in a bath of circulating mineral'oil which is uniformly heated at a steady rate of 2 C. per minute.

The softening temperature is observed-as tha not is dried at 100 C. for24 hours under high I tioned in this specification are determined by this method.

A similar methyl methacrylate polymer poly- The above example is repeated using varying quantities of trichloroethylene. When the products are worked up and molded as above, injection molded softening temperature specimens are obtained which soften as shown in the following table:

The ingredients for a granular polymerization are assembled as follows l\ (in Parts Distilled water 4800 NazHZPO4J2HzO 1% Water solution of 65% sodium salt of polymethacrylic acid. 480 (b) Parts Methyl methacrylate monomer 2786 2-Chloropropene 14 Cc) Parts Benzoyl peroxide '7 The ingredients are charged into a kettle as described in Example I and polymerization is conducted in a similar manner. Heat is applied as in Example I and after the heat has been cut off the exothermic polymerization reaction causes a surge of temperature and pressure to 125 C. and lbs/sq. in., respectively. The bulk of the polymerization takes place under these conditions. The resulting polymeris worked up and converted to molding powder and injection molded in the manner described in Example I. When the heating cylinder delivers polymer at 230 C. into the cold die, satisfactory moldings are produced under 25,700 lbs./ in. piston pressure. The moldings obtained are brilliantly clear and are faithful reproductions of the die cavity. Injection molded strips from the 2%1: K" x 0.065" die soften at 99 C. according to the softening te perature determination described under Examp 1 A similar methyl methacrylate polymer polymerized as above but without the addition of of 2-chloropropene.

Example II is repeated using quantities worked up and molded as above, injection molded softening temperature specimens are obtained When the products are methyl methacrylate A polymerization is carried out using the following ingredients:

() Parts Distilled water 4800 Na:HPO4.l2HaO 56 1% Aqueous solution of the 65% sodium salt of polymethacrylic acid m 600 (1)) Parts Methyl methacrylate monomer 2772 1-Chloro-3-hydroxypropene-1 28 (c) Parts Benzoyl peroxide 7 The above ingredients are polymerized according to the general method described in Example I. The bulk of the polymerization takes place at a temperature of 121 C. under a pressure of 48 granular polymer is worked up and injection molded according to the general me od described in Example I, polymer delivered from the heating cylinder at 220 C. is readily injection molded into specimens of excellent appearance under a piston pressure of 23,300 lbs/sq. in. Aspecimen 2%" x b" x 0.065" is found to soften at 87 according to the method described in Example I. A correspondingunmodified control polymer softens at 74 C.

Exmnl IV The following solutions are made up:

(a) Parts Distilled water 4800 NamPOamHsO 56 1% Aqueous solution of the 65% sodium salt of polymethacrylic acid. 600 (12) Parts Methyl methacrylate monomer 2772 Methyl alpha-chloracrylate monomer 28 (c) Parts Benzoyl peroxide 7 The above ingredients are polymerized in the general manner described in Example 1. Durin the exothermic polymerization reaction the bulk of the polymerization takes place at a tempera-- ture of 126 C. under a pressure of 55 lbs./sq. in.

when the resulting granular polymer is worked up and injection molded, polymer delivered from the heating cylinder into the injection die at 200 C. molds readily under a piston pressure of 23,300

lbs/sq. in. An injection molded specimen 2 x 9611' x 0.065" is found to soften at 89 C. according to the softening temperature determination described under Example I.

The above example is repeated using 2% of methyl alpha-chloracrylate monomer (based on monomer) instead of 1% and an injection molded specimen 2 x Vi" x 0.065" is found to soften at 95 C. as compared to 74 C. for an unmodified control.

5 rylate in It will be understood that the above examples are merely illustrative and that the present invention comprises, in its broader. aspects, the polymerization of monomeric methyl methacthe presence of small amounts of any unsymmetrical aipha-olefinic compound in which one of the carbon atoms of the double bond carries a single halogen atom, to obtain a product especlally'suited for injection and compression molding.

The invention contemplates the use of any unsymmetrical alpha-elefinic compound as here-' in defined. The structure and constitution of the rest of the molecule of the halo-olefin is relatively immaterial as long as it does not contain chromophoric structures which would impart color to the product or functional groups that inhibit the polymerization of methyl methacrylate. In order to avoid the cumbersome and impractical use of gaseous modifiers, it is preferred to employ halo-olefins of molecular weight above 70 and chloro-olefins are preferred.

Compounds which are closely related chemically to the herein specified halo-olefins but which do not fall within the specific definition of being unsymmetrical alpha-olefinic compounds in which one of the carbon atoms of the double bond also carries a single halogen atom, fail to produce significant improvements in 3 methyl methacrylate polymers. Thus if the process of Example II is repeated using small concentrations of other chlorine containing compounds closely related to 2-chloropropene, trichloroethylene, etc., the following results are 35 obtained:

Softening temperature of injection moldedspecimen 2%x% X0065 2 carbon tetrachloride In general, the use of the specific halogenated olefins defined above as modifiers for methyl methacrylate according to this invention leads to polymers that show superior heat resistance in injection molded specimens. However, the concentration of the particular halogenated olefin has an important bearing on the properties of the molded product, obtained with different concentrations for each specific halogenated olefin. This is obvious in view of the differences in activity of the various e modifiers contemplated and their diflering relative molecular weights. In general, the concentration of specific halogenated olefin required is greater the higher the molecular weight of the specific halogenated olefin. But only relatively small amounts of the modifiers defined above are required, and the present invention contemplates the use of these modifiers in concentrations only up to about 3% by weight of the methyl methacrylate monomer. Particularly with very active modifiers, concentrations as low as 0.01%

produce significant improvements.

It is preferredto carry out the present invention by polymerizing methyl methacrylate comand equivalent eflects are 7 8 be from 100 0. up to temperatures of 150 C. or size may be used on products oi the present inhigher, with a temperature oi. at least 125' C. vention. preferred, in closed reaction equipment suitably Plasticizers or lubricants may be added to the designed to withstand the autogenous presproducts of this invention either during polysures developed. As the reaction temperature is merization as in Example I or during subsequent increased, theconcentration ot benzoyl peroxide mastication of the polymer 'on heated rolls. Suitabout 1%, (based on methyl methaerylate monosimilar manner for imparting special appearance mer) at 100 C. to 0.5% in the range of 110 C. eil'ects to the polymer.

to 115 C. and to 0.25% in the range of 120 C. 10 The products of this invention are useful as to 130 0. Above this temperature the catalyst molding powders for the preparation oi valuable concentration is further decreased, and at temarticles by the known methods of compression peratures of 150 C. and above the catalyst may or, injection molding commonly used for shaping catalyst concentration s selected which yields process oi injection molding, the products of this tion for optimum molding properties. ously known methyl methaerylate polymers in C alys s other n oy Peroxide are that the molded articles show a much greater used in corr on ng n V' 'h s didodecyl resistance to distortion by heat while at the peroxide, diethyl peronide, hydrogen peroxide, same time being optically horn and free persuli'uric acid and its salts, and similar catafrom discoloration. The products of this invenlysts may be suitably used.

The use of dispersants such as the 65% sodium rods. salt of polymethacrylic acid is optional. The As many apparently widely diirerent embodiamount req ired gene ally vari s in inverse ratio ni'ents of this invention may be made without to the effectiveness of agitation during polymerdeparting from the spirit and scope thereof, it is ization. The amount and eifectiveness of the disto be understood that the invention is not limpersant selected, if any. is preferably o mi ited to the specific em odiments thereof except a as to prevent the formation ofa permanent susas defined in the appended claims.

pension and merely suincient to keep droplets I claim:

of the methyl methacrylate compositions from 1. Process of preparing a modified methyl coalescing during polymerization. The water methacrylate omposition which comprises polydispersant is the most effective. A pH of less 3.0% by weight of the monomer of trichloroethyl than 4 or above 10 is generally to be avoided ene at a temperature 01 100? C.-150 C. under because of the tendency of methyl methacrylate autog'enous pressure. monomer to hydrolyze under these conditions. 2. A modified methyl 'm thacr late molding The products of this invention can also be precomposition adapted to be molded into articles pared by other methods of polymerization, such 40 having a high resistance to distortion by heat Any of the customary methods for converting weight of the monomer of trichloroethylene while granular I thermoplastic polymers to injection dispersed in water, said polymerimtion being carmolding compositions such as by masticatingon a ried out at. a temperature oi C.- C. under heated rolls or by w 1 thrzmgh a screw stutter autogenous pressure. s followed vby cooling and chopping to convenient FREDERICK L-JOHNSTON. 

